Method of forming porous cemented metal powder bodies



l Uiedeew Joseph i P.v Scanlan, Yonkers, and `Louis Thisv invention relates tovsintered metal powder bodies which have interconnectedpores andare ductile,l coinable, and to lthe process ofv making such bodies to shape within narrow tolerances.

thermosetting resin.' 'Ihis particles with a solution of the'resin in the' soluble incompletely set, or Bf state while permittingthe solvent leaving -a coating of the resinon the particles. As such va resin solution is mixed witlr'the metal to evap orate',

particles while stirring,la plastic dough tirsty forms which Among the objects of the invention is to provide a cemented metal Aparticlebodywhich is porous in some parts and ofdilferent porosityv or of no porosity in other predetermined parts thereof, and to'provide a process for v making such a'body.

products, etc., and the urea aldehyde resins such as the urea formaldehyde condensation products and the melamine condensation products. Thermosetting resins' .of

graduallyibecomes granular again as the solvent continues tok evaporate.Y VAfter all the solvent has been driven off, the particles are screened'to lumps and 'the powdery is ready to The forming is done jby compacture pressure such as, 45.0`p. s. i. (pounds per squarev inch) for example or less. Thereafter, the compacted product is heat treated toset or vcure'the resin.y This pro-' duces -a resin-bonded molded product which has `all the appearance and shape of the finished produce of Figs.` 1A and 2, for example, except for the luster and color.

be forme'd'to shape. under relatively low The resin-bonded molded product is then sintered in areducing atmosphere to provide the shaped'l sintered metal body as shown in Figs-l and 2. AFig. 1 shows a porous bearing'element 10 andFig.r 2 shows la porous cup iilter device 11, each exemplifying a molded porous product of the invention.' 'j j v Porous molded products of the inventionmay be combined with a continuous metallic reinforcing structure which is integrally united to and/or embodied inthe the silicone epoxy or polyester type may alsoV be employed, but thermoplastic Iresins are unsuitable. The exact amount of resinadded is not kextremely. critical since the resin does not appear in the final product, but variation of the resins content represents a convenient method of varying ther degree of porosity of the end product. They addition of l/zl to 4% of resin, by weight to the metal powder, proved very satisfactory.

` v Reinforcing `sheets or screens may be bonded tothe sintered powder particle bodies by incorporating the Said sheets into said body at any time in the manufacturing process prior to linal sintering.

f vThe articles made accordingto the invention maybe from 10% to 55% porous. The porosity may be controlled by the size and size distribution of the par ticles employed, and lalso by the amount of resin and amount ofpressure employed.`v f f The foregoing andr otherobjects of theinvention will bebest understood fromy the following description of exemplitications of the same when read in connection with the accompanyingv drawing in which:

Fig. 1 is a partially cross-sectional view of a bearing madeaccording tothe invention; l Fig. 2 is a similar view of a -iilter elementmade according to the irn'fention;v t

"Fig 3 is a similar View yof a modified form oflter element; s Y 1 Y' Fig. ,4 is a similar view of lafmodiied form of bearing; vrFig.v 5 is a similar view, of another modied formv of bearing; .f l f Fig. l6 is a cross-sectional view illustrating a step in ,the formation of the bearing of Fig. 5 ,and

Fig. 7 is a cross-sectional view illustrating another step in the process of making the bearing of Fig. 5.

Afterftliefmetal particles to be formedinto a porous, product'have'Vv been selected, they are coated with'a Y in the inner reinforcing member 14, and

bonded particle material of the molded porous body such as shown in Fig. 3. In this device 12 the outer portion 13 comprises the porous sintered metal body and the inner layer comprises a metal cup number of perforations 15. Woven wire mesh may also be employed as reinforcing material. is pressed into the outer portion13 vduringthe formation of the outerportion 13 or at any time subsequent thereto but prior tothe final sintering. The outer portion 13 may be partially sintered before pressing the inner layer 14 therein. The cup 14 may contain openings of any shape such as the small holes or openings 15. The porosity of the finishedv product may be controlled by predetermining the size and shapeof the openings 15 and 16 the permeability of the inished product with respectl to gases or liquids may be controlled, and varied from one other by the number and-size of the openings.

The articles made according to the invention may `also be reinforced from the outside as shown in bearing 10 of Fig. 4 which s similar to the Vdevice 10 of Fig. 1, 'except for the outer reinforcing member 18. 'I'his reinforcing member 18 is .incorporated into or* cemented to the bearing 10 in the same way as the inner cup 14 is cemented to outer portion 13 in Fig. 3.

Since the pores of the bodies are interconnected, said pores may be lled by processes v which permit the capillary action ofthe pores tocause the same to be infiltrated with molten metal. Where onlyv sa portionofthe article` is to be inltrated, the passageof molten copper, for` example, into the pores of a ferrous article may be stopped at a barrier comprising silver powder, the silverl being a metal whichr suppresses ow of iniltrant copper metal past the region whereinsilver is present in addition to the kbase v metal powder. Thus, a layer of silver powder'may be incorporated into the body at the time the body is first shaped. As an example, the bearing l40.

of Fig. 5 of a metal, such as a steel alloy, for example` having the porous portion41, the silvercontaining barrier portion 42 andthe copper-filled portion43may be Next, steel particles coated with'resin plus/2%, to.10%

2,845,346 i *rented*J11r2911953 maybe done bymixingthe remove agglomerated 14V containing sa The inner cup- 14' location to an- 3 of silver particles are introduced in suicient amount to form a vnarrow barrier region 42 ending at level 43', and then resin coated steel particles such as introduced into region 41 are introduced into barrier region 43. The amount-of silver employed will depend on the sintering temperature, `time of sintering, and dryness of the atmosphere. The product is formed into a resin-bonded article as described above, but the copper impregnating of the portion 43 may be combined with the sintering. Instead Vof using a barrier containing silver particles, it is also possible to use silver additions for the entire portions of the part which lare not supposed to be infiltrated.

For impregnating or infiltering the region 43 with copper (simultaneously with or subsequent to the sintering) the set-up shown in Fig. 6 may be employed. The copper infiltrant member S8 may be separated from the article by a piece -of iron 57 so that the copper, when molted, will dissolve all the iron it is capable of dissolving before coming into contact with the ferrous region 43 which is to be infiltrated. This precaution prevents the molten copper from dissolving or corroding the ferrous region 43 into which it passes. Capillary faction of the pores of region 43 draw the molten copper into the pores, but the copper will not pass through barrier region 42. As indicated above, the copper impregnating step may be performed simultaneously with the sintering step or the copper impregnating may be performed as a separate step,

The following examples illustrate specifically how the products of the invention are made.

Example 1 A phenol formaldehyde resin in the B or soluble state is dissolved in acetone. Phenolic resins in this state of condensation are available commercially. Stainless steel powder of -325 rnesh particle size is placed in a mixing device and the acetone solution of the phenolic resin is added. Approximately l1/2% by weight of the resin is added for this example. The mixing first produces a putty-like dough. As the mixing is continued, substantially Iall the acetone evaporates and powder particles are again obtained. The substantially dry resincoated particles are then passed through a 60 mesh screen to remove large conglomerates. This powder is then filled into the cavity `of a mold, and compressed at around 450 p. s. i. to produce a cup-shaped element like that of Fig. 2. The mold containing the product is then transferred to a curing oven whereupon it is treated at 450 F. for about 30 minutes to cure the resin. The resinbonded article is then removed from the mold and placed n in a gettered boat containing activated ferrochrome as the gettering material. The boat and article is then sintered in a hydrogen atmosphere at around 2300 F. for 80 minutes. After sintering, the body is cooled in a hydrogen atmosphere for another period of 80 minutes. A porous filter element like that of Fig. 2 is produced.

Example 2 The process is conducted as in Example 1, except that before the resin-coated powder is pressed to shape in the mold, -a cup-shaped reinforcing element of perforated stainless steel is introduced therein. The article which results has the said reinforcing sheet bonded thereto.

Example 3 The process is conducted as in Example l or 2, except that nickel powder is substituted for the stainless steel powder.

Example 4 The process is conducted as in Examples 2 and 3, except that the stainless steel reinforcing sheet is coated with copper before being molded with the powder.

Example 5 The process is conducted as in Examples 1-4, except 4 that a portion of the finished product is inltrated. This is accomplished by introducing a barrier layer of powder containing silver as shown at 42 in Fig. 6. Prior to sintering the resin-bonded article, a piece of copper separated from the region 43 by a layer of iron is placed on the bearing as shown in Fig. 7. The resultant article will be found to be impregnated with copper in the region 43. Prior to sintering in this way, no difference could be distinguished between the layers 41, 42, 43. After the sintering operation, irregular lines are discernible at 5; and S3 (Fig. 6) and the region 43' will be found to have a distinct copper color.

When this article is made primarily of stainless steel as in this example, it is found that the copper impregnated or infiltrated region is easier to machine than the more porous stainless steel region 41. The products of the above examples may be finished by coining and polishing,

The products have high strength and within very narrow limits are substantially identical with the products as shaped in said original mold. The bodies can be made to very close tolerances.

The features and principles underlying the invention described above in connection with specic exemplifications will suggest to those skilled in the art many other modifications thereof. It is accordingly desired that the appended claims shall not be limited to any specific feature or details shown or described in connection with exemplifications thereof.

We claim:

1. A process of making a shaped body out of a sintered porous base-metal particle skeleton having at least one region which contains inter-connected pores which are free of inliltrant metal and at least one other region containing inter-connected pores filled with an infltrant metal having .a lower melting point than said base metal, the procedure comprising the steps of providing a shaped skeleton of base metal particles bonded together by partial sintering, providing said skeleton with at least two regions separated by a barrier region containing particles of an addition metal which at the elevated temperature of molten infiltrant metal suppresses the flow of molten infiltrant metal into the pores of said barrier region, completing the sintering of said skeleton while providing a molten inliltrant for inltration into the pores of said body from one side of said barrier region whereby said barrier region prevents the molten infiltrant metal from infiltrating into said other region past said barrier region.

2. A process of making an accurately shaped body out of a sintered porous base metal particle skeleton having at least one region which contains interconnected pores which are free vof infiltrated metal and at least one other region containing interconnected pores filled with a metal of lower meltingpoint than said base metal comprising the steps of providing an accurately shaped skeleton of hase metal particles bonded together by partial sintering, providing said skeleton with at least two regions separated by a barrier region containing particles of an addition metal which at the elevated temperature of molten copper suppresses infiltration of molten copper into the pores of said barrier region, completing the sintering of said skeleton while providing molten copper for infiltration into said body from one side of said barrier region whereby the said barrier region prevents the molten copper from infiltrating into the other region past said barrier region.

3. The process as claimed in claim 2, wherein the porous skeleton consists of bonded ferrous particles.

4. A process of making an accurately shaped body out of .a sintered porous base metal particle skeleton having at least one region which contains interconnected pores which are free of infiltrated metal and at least one other region containing interconnected pores filled with a metal of lower melting point than said base metal comprising the steps of providing an accurately shaped skeleton of 6 base metal particles bonded together by partial snter- 5. The process as claimed in claim 4, whereinthe Y ing, providing said skeleton with at leastl two regions porous skeleton consists of bonded ferrousrparticles. l separated b a barrier region containing silver articles s which at thsel temperature of molten copper supress in- References cned m the me of this Patent filtration of molten copperinto said barrier region, com-V 5 UNITED STATES PATENTS pleting the sintering of said skeleton while providing 2,363,337 Kelly Nov, 21, 1944 molten copper for infiltration into said body from one 2,386,544 Crowley Oct. 9, 1945 side of said barrier region whereby the said barrier region 2,401,221 Bourne May 28, 1946 prevents the molten copper from inltrating into the 2,518,253 Reis Aug. 8, 1950 Y other region past said bam'er region. 10 2,593,943 Wainer Apr. 22, 1952 

1. A PROCESS OF MAKING A SHAPED BODY OUT OF A SINTERED POROUS BASE-METAL PARTICLE SKELETON HAVING AT LEAST ONE REGION WHICH CONTAINS INTER-CONNECTED PORES WHICH ARE FREE OF INFILTRANT METAL AND AT LEAST ONE OTHER REGION CONTAINING INTER-CONNECTED PORES FILLED WITH AN INFILTRANT METAL HAVING A LOWER MELTING POINT THAN SAID BASE METAL, THE PROCEDURE COMPRISING THE STEPS OF PROVIDING A SHAPED SKELTON OF BASE METAL PARTICLES BONDED TOGETHER BY PARTIAL SINTERING, PROVIDING SAID SKELETON WITH AT LEAST TWO REGIONS SEPARATED BY A BARRIER REGION CONTAINING PARTICLES OF AN ADDITION METAL WHICH AT THE ELEVATED TEMPERATURE OF MOLTEN INFILTRANT METAL SUPPRESSES THE FLOW OF MOLTEN INFILTRANT METAL INTO THE PORES OF SAID BARRIER REGION, COMPLETING THE SINTERING OF SAID SKELETON WHILE PROVIDING A MOLTEN INFILTRANT FOR INFILTRATION INTO THE PORES OF SAID BODY FROM ONE SIDE OF SAID BARRIER REGION WHEREBY SAID BARRIER REGION PREVENTS THE MOLTEN INFILTRANT METAL FROM INFILTRATING INTO SAID OTHER REGION PAST SAID BARRIER REGION. 